CAT Roof Support 3D Tilt Monitor Operation & Maintenance Manual - PDF DOWNLOAD

Media-ID: EM030017-00-EN Doc.-No.: 1999 001 197 BA 00-01 Nov. 2019

3D Tilt Monitor Integra Hebden

Serial-No.:

LWF01512 - 01648, LWB00174 - 00179

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Table of content

Table of content 1 Introduction.................................................................................................. 4 2 System Components................................................................................... 5 3 Shield Calibration and Calculated Points ................................................. 6 4 Geometry Index ......................................................................................... 13 5 Shield Types .............................................................................................. 14 6 Procedures................................................................................................. 15 6.1 Installing inclinometer software using the Sub System Booter Software ......... 15 6.2 Configuring a new installation using the Sub System Booter software............ 17 6.3 Updating Hm1, Hm2 and Geometry Index values with a PMC-R ....... 18 Media-ID: EM030017-00-EN / Caterpillar Global Mining Europe GmbH 2019 ©

6.4 Changing a 3D Tilt Monitor ................................................................. 20 6.5 Changing a 3D Tilt Sensor.................................................................. 21 7 Measured Values Menu............................................................................. 22 8 PMC-R Motion Monitoring Parameters.................................................... 23

3D Tilt Monitor Integra Hebden

1

Introduction

1 Introduction The 3D tilt monitor system provides the height measurement at 3 different positions on a shield. Calibration of the system is achieved by taking two measurements on the shield and inputting these heights into the local PMC-R. The purpose of the tilt monitoring system is To reduce the likelihood of damaging in-shield components and spill trays caused by shields lowering too far.

To provide a true height that will be used for shearer anti-collision protection.

To detect unplanned movement of a shield.

To provide accurate shield height data for analysis.

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This document provides an overview of the shield inclinometer system and its interaction with the PMC-R system and is intended for Integra Hebden.

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System Components

2

2 System Components Shield Layout

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Fig. 1: Shield Layout

3D Tilt Monitor Overview Fig. 2: Overview

For Additional information regarding LED activity on the 3D tilt monitor refer to the ‘Miscellaneous information about the 3D Tilt System’ manual.

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3

Shield Calibration and Calculated Points

3 Shield Calibration and Calculated Points

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The tilt monitor calculates the H1, H2 and H3 values once the true measurements of Hm1and Hm2 have been entered into the tilt monitor.

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Shield Calibration and Calculated Points

3

Calibration measuring points A guide tool specific to the shield type is used to allow the calibration point to be easily found in the shield.

Common Hm1 and Hm2 Base measuring points

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Fig. 3: Measuring points

The Common Hm1 and Hm2 calibration point on the base of the shield is found on the Left hand side of the base (looking at coal) on the base rise.

Fig. 4: Hm1 and Hm2 measuring points

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3

Shield Calibration and Calculated Points

This point can be found by placing the appropriate form for the shield type in position.

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Fig. 5: Calibration point form tool

Fig. 6: Correct placement of calibration form tool for Hm1 and Hm2 calibration point

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Shield Calibration and Calculated Points

3

If the form tool is not available there is another option to measure the HM1/HM2 base point, see below:

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Fig. 7: Base point (x)

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3

Shield Calibration and Calculated Points

Hm1 canopy measuring point The Hm1 calibration point on the canopy of the shield is found on the left hand side of the canopy (looking at coal).

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Fig. 8: Hm1 canopy measuring point

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Shield Calibration and Calculated Points

3

Hm2 caving shield measuring point The Hm2 calibration point on the caving shield is found on the left hand side (looking at coal).

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Fig. 9: Hm2 caving shield measuring point.

Important information Identical base measurement point The calibration point for the Hm2 measurement in the base of the shield is in the same position like for Hm1. This applies to all shield types.

Equipment needed to calibrate the shields Specific equipment is supplied to allow accurate calibration of the 3D tilt system.

Measuring Sticks – These allow accurate measurements to be made for shield height calibration.

Fig. 10: Measuring stick

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3

Shield Calibration and Calculated Points

Forms are used to determine where the measuring stick should be positioned on the base of the shield.

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Fig. 11: Base measuring point form

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Geometry Index

4

4 Geometry Index The Geometry index is a number that is assigned to each type of shield on the face. This number is configured in the 3D tilt monitor when the parameters are set for the project and shield type using a PMC-R application or subsystem booter.

Each PMC-R in a shield that is of a shield type that has a geometry different to a run of face shield must be fitted with a specific code plug. The code plug is linked to a Geometry Index number.

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Once communications are established between a PMC-R and 3D tilt monitor the Geometry index number set in the Monitor is transmitted to the PMC-R. The PMC-R can then check that the setting in the monitor matches the shield type set by the PMC-R after referencing its code plug.

This ensures that the geometry that is applied when the 3D Tilt Monitor calculates the heights of a shield is correct for the particular shield type. If there is a discrepancy between the Geometry index configured in the 3D tilt monitor and the Geometry index derived by the PMC-R than a ‘Tilt Table Mismatch’ error will occur.

The Geometry index comparison is made approximately every 10 seconds.

Shield Description

Drawing number

Geometry Index

PMC-R code Plug Part No.

Code plug number

No box connected to PMC-R

N/A

-1

N/A

N/A

Run of Face (4-140)

7420.239.000.00.03

10

N/A

N/A

Gate End Shields (1-3) & (141-143)

7420.239.000.00.04

11

634870 / 634867

220 or 240

The Active code plug on a PMC-R can be seen in the Diagnostics menu. In this example 220 is installed.

The Geometry Index number being transmitted by the 3D Tilt Monitor can be viewed in the Motion Monitoring Menu.

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5

Shield Types

5 Shield Types Integra has two different types of Roof Supports with different geometries.

Gate End Shields Run of face shields

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Fig. 12: MG gate shields highlighted (shields 1, 2 & 3)

Fig. 13: TG gate shields highlighted. (shields 141, 142 &143)

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Procedures

6

Installing inclinometer software using the Sub System Booter Software

6 Procedures 6.1 Installing inclinometer software using the Sub System Booter Software It is necessary during initial installation or when a software update is required to update the software in all 3D monitor box’s on the face. This can only be achieved underground if the PMC-R system is connected to the Ethernet network via a PMCP or an I.S Switch.

The following steps must be taken to achieve this. This procedure assumes that the Sub system Booter software and bootpmc.exe files is installed on a PC that can connect to the PMCP or I.S Switch which the PMC-R system is connected to.

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1. Check that there is a complete PMC-R network and that all in shield electrics are complete to allow communications between the PMC-R’s and 3D tilt monitors and between the 3D tilt monitors and 3D tilt sensors. Ensure all tilt monitor are powered up.

2. Ensure that a full PMC-R parameter audit is carried out and the means to reinstall the PMC-R software is available before commencing.

3. On the PC that the software will be installed from a folder should exist populated with the following files ( .dbtpmc file may be different depending on version of software being installed):

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6

Procedures Installing inclinometer software using the Sub System Booter Software

5. Select the PMCP button.

6. Enter the IP-Address of the master I.S switch or PMCP on the network that the PMC-R system is connected to.

7. Select ‘PMC-R (11)’ and then click O.K.

8. Clicking erase will erase the program installed on every ‘PMC-R’. All PMCR’s will then reboot.

9. Once the PMC-R’s re-connect the ‘Start Transmission’ button will be available for selection. Click this button to begin installing the software into all connected PMC-R’s.

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4. Open bootpmc.exe.

Procedures

6

Configuring a new installation using the Sub System Booter software

10. Once installed all PMC-R’s will re-boot and the red Jumbo LED will be lit on the PMC-R.

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11. The PMC-R’s will begin to boot the program to the 3D tilt Monitor box automatically and once this is complete the Jumbo LED will turn off on the PMCR’s individually. Once complete the 3D tilt monitor will the boot the new software into the sensors if required.

12. Every PMC-R must now be checked to see if the Jumbo LED is switched off. This is indication that the software has booted successfully from the PMC-R into the 3D Monitor box.

If any Jumbo LED’s are still lit the connections must be checked between the Port A2 of the PMC-R and port X1 of the 3D tilt monitor. It must also be checked that the 3D monitor box has power connected to it.

A quick check is to look at both of the power LED indications on the 3D Monitor box. These should both have white LED’s illuminated.

Note – The MG server and TG sever will both still have their jumbo LED’s illuminated as there are no 3D tilt monitor box’s connected to these PMC-R’s 13. If the software update has occurred on an installation that had had the 3d monitor boxes previously configured it may not be necessary to make any configuration changes using the sub-system application installed in the PMC-R. If no configuration changes are required to be made the PMC-R roof support application can now be re-installed.

14. If configuration changes are required such as geometry index configuration, refer to Procedure – Configuring a new installation using the subsystem booter application and reference the mine specific ‘Geometry index’ section in this manual.

6.2 Configuring a new installation using the Sub System Booter software It is necessary during a new installation to set the parameters in the 3D Tilt Monitors. This can only be done using the PMC-R subsystem Booter application on the PMC-R once the 3D Tilt monitors have been updated.

Refer to the ‘PMC-R Subsystem Booter for the 3D tilt system’ manual to gain familiarity with the menu structure and changing of parameters. This manual also describes how to enter the Hm1 and Hm2 calibration values and view the H1, H2 and H3 values.

Note – The Hm1 and hm2 calibration values can also be entered through the PMC-R roof Support application.

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6

Procedures Updating Hm1, Hm2 and Geometry Index values with a PMC-R

To update the geometry Index’s for the longwall 1. Set the global parameter for the correct mine and shield type from the list for the run of face shield and then press the enter key. This is a global parameter that will be sent to every 3D Monitor connected to a PMC-R on the network.

3. Once this configuration is complete proceed to re-install the PMC-R Roof Support application.

6.3 Updating Hm1, Hm2 and Geometry Index values with a PMC-R Calibration of the 3d tilt system is achieved by applying the following steps: 1. Power must be on for the PMC-R and shield inclinometer components.

2. Ensure the PMC-R and 3D tilt box are communicating by checking the Rx/ Tx LED on the tilt monitor box and that the LED indications for the sensors are healthy. Also, check the measured values menu on the PMC-R and to see if there are current reading for H1, H2 and H3.

3. Navigate to the tilt monitor menu and check that the correct tilt geometry is being transmitted from the 3D tilt monitor.

This can be determined by navigating to the motion monitoring menu using

the key and then pressing the ometry Index parameter.

key to access the Ge-

The value displayed should match the geometry index number specified below for the particular shield type.

Run of Face Shield (4– 140) = 10

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2. It is now required to send the correct Geometry index to the Gate end shield 3D Tilt monitors. This is done by setting the local parameter for each individual gate shield at its respective PMC-R. For Integra this should be shields 1-3 and 141-143 set to 11.

Procedures

6

Updating Hm1, Hm2 and Geometry Index values with a PMC-R

Face End (1-3 & 141-143) = 11 If the incorrect Geometry index is being transmitted from the 3D tilt monitor than the correct parameters must be set before continuing.

Press Enter in the Geometry Index line and type in the correct Geometry Index go to the next line and press N to transmit the geometry Index to the monitor box.

Hardware Code plug necessary!

4. Determine the true Hm1 and Hm2 measurements for the shield using the appropriate measuring tools for the particular shield type.

5. Enter the Hm1 measured value into the PMC-R using the following steps.

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Navigate to the motion monitoring menu using the

Press the

key.

key and input the L3 password followed by the

key.

Navigate down the menu using the eter is displayed.

Press the

key until the following param-

key.

Input the value of the Hm1 measurement in millimetres and then press the

key.

Press the

3D Tilt Monitor Integra Hebden

key so that the following parameter is displayed.

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6

Procedures Changing a 3D Tilt Monitor

6. Enter the Hm2 measured value into the PMC-R .This is done by applying step 5 to the ‘Ref.hight Hm2’ and ‘Set Ref.Hm2’ parameters instead.

7. To complete the process check the Hm1 and Hm2 measured values in the measured values menu correspond closely to the entered values.

6.4 Changing a 3D Tilt Monitor Equipment Required: 3D Tilt Monitor Staple Remover Measuring Sticks 10mm Allen Key 19mm Spanner.

When changing a 3D tilt monitor the following steps should be taken: 1. Remove the defective 3D Tilt Monitor taking note of the cable connections.

2. Install the new 3D Tilt Monitor and connect the cables.

3. Follow the procedure ‘Procedure – Setting Parameters in a 3D Tilt Monitor Box’.

4. Check the Motion Monitoring Menu read only parameter ‘Geometry Index’ and check that this matches.

5. Follow the procedure ‘Procedure – Updating the Hm1, Hm2 and Geometry Index values with a PMC-R’.

6. The shield heights should now be calibrated. Check the measured values for H1, H2 and H3 in the measured values menu. These should correspond with the values which are measurable at the three different points in the shield by using the correct measuring stick. The different between the displayed value and the measured value should be not bigger than +/-10mm directly after the calibration without any change in the shield height. After moving the shield to different heights the different should be not bigger than +/- 50mm.

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3D Tilt Monitor Integra Hebden

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Now press the key. This will transmit the value entered in Ref.hight Hm1 to the 3D tilt monitor. Once the monitor is updated the value will appear between the brackets in the display.

Procedures Changing a 3D Tilt Sensor

6

6.5 Changing a 3D Tilt Sensor Equipment Required: 3D Tilt Sensor Measuring Sticks 19mm Spanner.

When changing a 3D Tilt Sensor the following steps should be taken: 1. Remove the defective 3D Tilt Sensor.

2. Install the new 3D Tilt Sensor and connect the cable. Once communication is established with the 3D Tilt Monitor the Monitor will update the Sensor if required.

3. Follow the procedure ‘Procedure – Updating the Hm1, Hm2 and Geometry Index values with a PMC-R’.

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4. The shield heights should now be calibrated. Check the measured values for H1, H2 and H3 in the measured values menu. These should correspond with the values which are measurable at the three different points in the shield by using the correct measuring stick. The different between the displayed value and the measured value should be not bigger than +/-10mm directly after the calibration without any change in the shield height. After moving the shield to different heights the different should be not bigger than +/- 50mm.

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7

Measured Values Menu

7 Measured Values Menu Measured value of H1, H2, H3, Hm1 and Hm2 can be seen in the measured values menu on the PMC-R. This can be used to view the calculated heights being transmitted from the 3D tilt monitor.

Additional values that can be seen in the menu are Tilt_alpha1 which displays the angle of the base in the advancing direction (in deg) and tilt_beta which displays the diference in Angle between base and the Canopy (in deg).

The Hm1 and Hm2 raw values have been provided in the measured values to allow calibration accuracy to be tested.

Re-calibration is required after the replacement of any sensor or a 3D Tilt Monitor.

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Fig. 14: Measured Values Menu

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PMC-R Motion Monitoring Parameters

8

8 PMC-R Motion Monitoring Parameters There are several parameters that are associated with the 3D Tilt System. All of these parameters can be found in the Motion Monitoring Menu on the PMC-R. There are also display only values that can be found in the measured values and Diagnostics menus.

This menu contains parameters that control the Shield motion monitor settings.

Pressure is shown in Bar Height is shown in mm Cylinder extensions are shown in % of full stroke

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Time is shown in 1/100th second.

This parameter controls the function of the Motion Monitor.

0 =Motion Monitoring is not Active 1 = Motion Monitoring provides indication only. (Monitoring) 2 = Motion Monitoring is Active – Dump valve is De-Energised.

This setting determines whether the Motion Monitor function is permitted on the shield.

Use the tion.

key to allow (ON) or turn off (OFF) the Motion Monitor func-

High level password This parameter sets the maximum distance the shield height is allowed to lower without a Shield Lower solenoid being energised before an unplanned movement is detected within the shield (Height H1 is monitored).

The reference point for this is the H1 height that is achieved on the last legs / tip valve activation.

The prop pressures would also be monitored and if either of the prop pressures is above Max.hydraulicPres (420) then the system would assume the shield was in yield and an unplanned movement would not be generated.

Hardware Key Required

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8

PMC-R Motion Monitoring Parameters

CONVERGANCE The ‘MMMaxTrDown’ parameter also determines the downwards travel required for either the H1 or H2 measurement over an unlimited time period for a ‘Convergence Warning’ to occur. Convergence is only monitored when the leg pressure is above Max.hydraulicPres .

This parameter sets the maximum distance the shield DA reed rod is allowed to travel without a Shield Advance or Conveyor Push solenoid being energised before an unplanned movement is detected within the shield.

The reference point for this is the % stroke that is achieved on the last ram out / advance valve activation.

Hardware Key Required This parameter sets the number of adjacent shields to check for Shield Advance and Conveyor push solenoid operations to determine if an unplanned movement has occurred if the MaxTrDA limit has been exceeded.

This parameter sets the maximum distance the flipper reed rod can change without a solenoid function not being active for Flipper extend or Flipper retract.

The reference point for this is the % stroke that is achieved on the last flipper valve activation. % Flipper Stroke Hardware Key Required.

This parameter sets the minimum Height at the canopy tip (H1 the shield can lower to before the lower solenoid is disabled. This will reduce the risk of the Shield impacting on the spill tray. A facewide message ‘min Height stop #ShieldNo’ will be created.

If H1 reached Lower and Tip Down is disabled.

0 = function disabled Height in mm Hardware Key Required This parameter sets the minimum Height the shield can lower to before the lower solenoid is disabled and an Alarm ‘min.Height Dump #’Shield No’ is sent through the face. This will reduce the risk of the Shield impacting on the spill tray.

0 = function disabled Height in mm Hardware Key Required.

This parameter sets the minimum Height at the rear canopy (H3) the shield can lower to before the lower solenoid is disabled. This will reduce the risk of damaging the components mounted within the shield. A facewide message ‘min Height stop #ShieldNo’ will be created.

If H3 reached Lower and Tip Up is disabled.

0 = function disabled Height in mm Hardware Key Required.

This parameter sets the minimum Height the shield can lower to before the lower solenoid is disabled and an Alarm ‘min.Height Dump #’Shield No’ is sent through the face. This will reduce the risk of damaging the components mounted within the shield.

0 = function disabled Height in mm Hardware Key Required.

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Hardware Key Required

PMC-R Motion Monitoring Parameters

8

DUMP OVERRIDE If a shield reaches the ‘MinHei.Dump’ limit the dump valve will be de-energized.

Both neighbours of the lowered shield will show ‘MinHeight_Oride (ENTER)’ in the default display. Pressing ENTER will override the dump command and energizes the dump valve again. The facewide messages changes from ‘MinHei.Dump #ShieldNo’ to ‘MinHei.Oride #ShieldNo.’ It will now be possible to set the shield.

This parameter is used to enter the reference Height Hm1 into the PMC-R so that it can be transmitted to the Tilt Box for Calibration of the unit.

Height in mm High level password

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This function is used to send the reference Height Hm1 to the Tilt Box to calibrate the height of the shield.

Pressing the

key will transmit the Value.

Height in mm High level password This parameter is used to enter the reference Height Hm2 into the PMC-R so that it can be transmitted to the Tilt Box for Calibration of the unit.

Height in mm High level password This function is used to send the reference Height Hm2 to the Tilt Box to calibrate the height of the shield.

Pressing the

key will transmit the Value.

Height in mm High level password The setting of this parameter determines the delay after a valve request has ceased that a recording of the actual relevant sensor value is made. The recorded value will then be referenced to detect excesssive movement of the shield without without an electro-hydraulic valve activation.

Hardware Key Required

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